Does anyone have the instructions for the 2k1Toaster Battery?

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by '04Prius, Jan 5, 2021.

  1. '04Prius

    '04Prius Junior Member

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    I actually went through that pretty extensively before I posted this, but it more talked about designing the pack than installing it. The file that was posted earlier worked awesome! Now I just need to do some troubleshooting with the sensors.
     
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  2. 8AA

    8AA Active Member

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    When you have the car apart again, you might want to use a multimeter to check resistance of the individual temperature sensors by measuring at the connector that goes into the ECU. Someone on here posted what the resistance should normally be, but I think the main thing is to check for an open circuit due to a broken wire or no resistance due to a short. I would imagine that the open circuit is more common with the wire breaking due to possible rough handling of the sensors. As far as not being clipped in properly, I would imagine that the sensor would still be reporting to the ECU, but might not be an accurate indication of the temperature of the cell.

    I don't know which sensor Circuit A would be, but it's possible that it's the air temperature sensor that is mounted on the top tension rod in the Gen2 Prius. I wouldn't rule that one out since the harness serves all four sensors.
     
  3. 8AA

    8AA Active Member

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    The only thing that I know about the metal plate is what was in the instructions from NewPriusBatteries.com. It indicated that you should be careful not to deform this plate since it's used by the car to make sure that the HV Isolation is in place. Maybe someone else on this board can shed some light on it's function. Maybe it is one of several grounding paths for the case and MAY cause an error code to be generated if it's not properly in place. It definitely serves a purpose, and if it were me, I would try to find a replacement.
     
  4. '04Prius

    '04Prius Junior Member

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    It was reporting to the ECU, but reading 20 degrees lower than the other two. I pulled the car apart and found it laying in the bottom of the battery case. I made sure it was secured properly this time. I found no corrosion in the ECU. I didn’t really feel the need to check all the sensors, and they now all read within 2° or so of each other. My hatch trim is starting to look pretty beat up, so I’ve been thinking about replacing that. I’ll try to find that strap at the same time
     
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  5. edthefox5

    edthefox5 Senior Member

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    Here's what the sensors should look like when complete.

    Sitting on my custom made hybrid battery rolling repair cart lol....

    I sold it on Craigs list to a guy who was rebuilding his battery. Cart height matched the rear lip of the car.

    The things we will do not to hurt our backs.
     

    Attached Files:

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  6. '04Prius

    '04Prius Junior Member

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    I decided to leave all my sensors on the bottom in the factory location. I’m hoping I don’t have to open it back up to mess with them again.
     
  7. Mendel Leisk

    Mendel Leisk Sunday driver DIY’r

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    Not sure what you mean by “on the bottom”. As it left the factory, or?
     
  8. edthefox5

    edthefox5 Senior Member

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    And that's exactly why 2K says mount them on top. Plus they probably sense heat better and will turn on the fan extending life as it says in 2K's manual.
     
  9. 8AA

    8AA Active Member

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    Although three of the temperature sensors were mounted on the bottom of the original modules, I also followed the recommendation from NewPriusBatteries to mount them on top of the new modules.

    Temperature Sensor Placement.JPG
     
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  10. Mendel Leisk

    Mendel Leisk Sunday driver DIY’r

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    That doesn’t seem right; someone was in there before you maybe?
     
  11. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Somehow just seeing this post now. As always you can email the store directly at [email protected] or submit the contact form or send us a text message. Or you can PM me.

    Everyone should receive a PDF of the instructions in an email with more tips and tricks. Always check your spam. The email goes out when the UPS label gets printed.

    Now that I am here, I should get updates. For some reason my @user doesn't ping me via email but once subscribed I'm good.
     
  12. 2k1Toaster

    2k1Toaster Brand New Prius Batteries

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    Most of the Gen-2 have the sensors on the bottom. They do fall off and then just sit on the plate below versus sensing anything and of course the bottom is the worst place to sense the temperature on a plastic thing that is not a uniform temperature with active air cooling.

    Toyota agreed and moved them to the top in the Gen-3 and they are still there now. Most Gen-2's have sufficient wiring slack to move them to the top. But not all. There is a tolerance in the factory wiring that just barely makes it work either way for most customers, but there are some unlucky few where the wires are just too short.
     
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  13. Mendel Leisk

    Mendel Leisk Sunday driver DIY’r

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    Ah thanks. Moving sensors to top would cool the battery more aggressively I’d think.

    For gen 2 owners with battery opened, if needed: just splice in some extra length to the sensor wires?
     
  14. edthefox5

    edthefox5 Senior Member

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    My G2 sensor harness had plenty of slack for some reason.
     
  15. 8AA

    8AA Active Member

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    Mine also had plenty of slack in the wires and I had no problem reaching the furthest module.

    BTW, very much enjoying the return to having the car operate like it did when it was new. I hadn't noticed how much its performance had degraded over the years and before the renovation it seemed to rely on the ICE more during acceleration. Now the battery kicks in and I get the nice surge in acceleration that I remember from the past.
     
  16. edthefox5

    edthefox5 Senior Member

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    Mine rocks. So nice to have full power again. Plus I installed a Super Bullet so it has even more get up & go. Its still a little slug of a car but I am wringing every bit it has now. Wife enjoys not taking you life in your hands to come off an on ramp and join traffic now. If your not flying around here you will get run over.

    Mine spends all day in green.

    I ev for a little bit and it comes right back super quick in green.
     
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  17. '04Prius

    '04Prius Junior Member

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    I had very little slack in the harness, so that’s mainly why I left the sensors on the bottom. I’m not too worried about the temp reading from the top to the bottom of the pack. I get that heat rises, but the sensors are pressed right up against the cells. I haven’t gotten the pack warm enough to even turn on the battery fan (I think I saw 80° once). The big test will be summers in New Mexico...
     
  18. Mendel Leisk

    Mendel Leisk Sunday driver DIY’r

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    How are you determining if fan is blowing, just by listening?
     
  19. '04Prius

    '04Prius Junior Member

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    Yes. I guess I should have been more clear. I haven’t heard it yet, although I can only hear it on setting 5 or 6. I’ve tested it to make sure it functions. Highest battery temp I’ve seen is 70°


    Does the car need to “relearn” the capacity of new battery? Everything seems to be working great, except it doesn’t seem to be draining the battery at all. I haven’t even seen it drop down to half. The car is now getting about 37mpg, but that was at 75mph with a 25-40mph headwind. I’ll see how it does on the latest tank I’ve put in it, ideally without the headwind.
     
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  20. edthefox5

    edthefox5 Senior Member

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    My NPB battery rarely moves off of all green or full blue bars.
     
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